Workshop Manual - TDI Engine Fuel Ingection ASZ

Service
Workshop Manual
FABIA 2000
1.9/96 TDI Engine, Fuel Injection
Edition 07.03
Engine code
ASZ
Service Department. Technical Information
Printed in Czech Republic S00.5328.00.20
Service
The Workshop Manual is intended only for use within the Organisation koda. It is not permitted to pass it on to other persons. KODA AUTO a. s.
Printed in Czech Republic S00.5328.00.20
FABIA 2000 1.9/96 TDI Engine, Fuel Injection
List of Supplements to Workshop Manual
FABIA 2000
1.9/96 TDI Engine, Fuel Injection
Edition 07.03
Supplement 1
Edition 07.03 09.04
Subject Basic Edition Modifications in Rep. Gr. 01 and 23
Article Number S00.5328.00.20 S00.5328.01.20
Edition 09.04 S00.5328.01.20
List of Supplements
List of Supplements
Edition 09.04 S00.5328.01.20
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Actuator diagnosis ..................................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault codes 16485 to 19561 ......................................................................... 01-2 Self-diagnosis III ........................................................................................ 01-3 - Readiness code ........................................................................................ 01-3 - Reading readiness code .............................................................................. 01-3 - Generating readiness code .......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Reading measured value block ..................................................................... 01-4 - Display groups 001 to 022, engine idling .......................................................... 01-4 - Display groups 004 through 011 at full load ....................................................... 01-4 - Display group 125 - CAN databus .................................................................. 01-4 page page page page page page page page page page page page page page page page 1 1 1 2 3 5 1 1 1 1 1 2 1 1 1 9
page 11
23 Fuel Formation, Injection

Diesel Direct Injection System ...................................................................... 23-1 - Safety measures ....................................................................................... 23-1 - Rules of cleanliness ................................................................................... 23-1 - Overview of fitting locations .......................................................................... 23-1 - Disassembling and assembling intake manifold .................................................. 23-1 - Removing and installing air filter .................................................................... 23-1 - Disassembling and assembling the air filter ....................................................... 23-1 Disassembling and assembling the unit injector ............................................... 23-2 Testing components ................................................................................... 23-3 Testing exhaust gas recirculation .................................................................. 23-4 - Connection diagram of vacuum hoses for exhaust gas recirculation .......................... 23-4 - Testing exhaust gas recirculation ................................................................... 23-4 Engine control unit ..................................................................................... 23-5 - Testing voltage supply for engine control unit .................................................... 23-5 - Replacing diesel direct injection system control unit -J248................................... 23-5 - Coding diesel direct injection system control unit -J248- ....................................... 23-5 - Activating and deactivating cruise control system (CCS) ....................................... 23-5 Testing auxiliary signals .............................................................................. 23-6 page page page page page page page page page page page page page page page page page page 1 1 1 2 5 5 6 1 1 1 1 1 1 1 2 3 4 1
28 Glow Plug System

Testing preheating system ........................................................................... 28-1 page 1
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Table of Contents
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Table of Contents
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01
01 Self-diagnosis
01-1 Self-diagnosis I
Properties of the self-diagnosis

The control unit for the diesel direct injection system is equipped with a fault memory. The fault memory is designed as a permanent memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication of the fault type. Fault table Chap. 01-2. Faults which occur only temporarily (sporadically) are displayed with the suffix /SP. Possible causes of sporadic faults are e.g. a loose contact or a temporary line interruption. If a sporadic fault no longer occurs after 50 engine starts, it is automatically erased. If faults are detected that are likely to influence the driving behaviour, the glow period warning lamp -K29- flashes. The stored faults can be read out with the vehicle system tester -V.A.G 1552-, -V.A.G 1551- or -VAS 5051 01-1 page 2. After the fault(s) has(have) been removed the fault memory must be erased 01-1 page 3. Note The following description only relates to vehicle system tester -V.A.G 1552- using the current program card. When not using the current program card or when using the fault read-out scan tool -V.A.G 1551- with integrated printer or using the vehicle diagnosis, measurement and information system -VAS 5051- a minor deviation in the display is possible.
Technical data of self-diagnosis

Interrogating control unit version
The control unit version is displayed once the vehicle system tester -V.A.G 1552 - is connected and the engine electronics control unit is selected 01-1 page 2.
Available functions when using the vehicle system tester -V.A.G 1552The conditions under which the desired functions can be selected are given in the following table.
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Precondition Operation 01 02 03 04 05 06 07 08 11
1)
Engine not running, ignition switched on yes yes1) yes no yes yes yes yes yes
Engine idling yes yes yes yes yes yes no yes no
Normal driving yes yes no no yes yes no yes no
Interrogating control unit version Interrogating fault memory Actuator diagnosis Basic setting Erasing fault memory Ending output Coding control unit Reading measured value block Login procedure
Only perform with the ignition on, if the engine does not start.
Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics
Special tools, test and measuring equipment and auxiliary items required
Vehicle system tester -V.A.G 1552- with cable
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts Earth connection to engine and gearbox O.K. Fuses according to current flow diagram O.K.
Procedure
1 4 7 C 2 5 8 O 3 6 9 Q
HELP
V.A.G.1552
Connect vehicle system tester -V.A.G 1552- with appropriate cable. Once the vehicle system tester has been connected:
V.A.G 1552 V.A.G 1551/3
Switch on the ignition or start 01-1 page 1 engine

depending on the function desired. Note
If data transfer errors are displayed as a result of an
S01-0045
incorrect entry, disconnect cable at vehicle system tester, connect it in again and repeat all the steps.
If one of the following messages appears in the dis-
play, test the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations or Operating Instructions of vehicle system tester.
Vehicle system test The control unit does not respond
HELP
01-1 page 2
Self-diagnosis I
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Vehicle system test Fault in communication set-up Vehicle system test K cable does not connect to earth HELP
HELP
Operate the vehicle system tester by referring to the

read-out on the display. Readout on display:
Vehicle system test HELP K cable doest not connect to pos. term.
Vehicle system test Enter address word XX
HELP
Enter address word 01 Engine electronics and confirm entry with Q . The control unit identification appears in the display, e.g.:
038906019LA = Part No. of the control unit (for current 038906019LA 1.9l R4 Coding 00102 EDC G000SG 1576 -> WSC XXXXX
control unit version see spare parts catalogue)

1.9 ltr. = engine displacement R4 = engine version (4 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models
with CCS)
000 = Control unit ID MG = Manual gearbox 1576 = Data status (Software version of the control
unit)
Coding 00102 = Coding variant of the control unit WSC XXXXX = Workshop code
Note
If the control unit version displayed does not corre-
spond to the vehicle, replace the control unit Chapter 23-5.

Incorrect coding of the engine control unit results in: Handling problems (jerky gear change, load change
jolts etc.)
Increase in fuel consumption Increase in pollution Storage of non-existent faults in fault memory
Interrogating and erasing fault memory

-V.A.G 1551/3, 3A, 3B oder 3C-
Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
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01
Only if the engine does not start:
Switch on ignition. Enter function 02 Interrogate fault memory and confirm entry with Q . The number of stored faults or No fault recognised appears in the display. If no fault is stored:
X faults detected!
Enter function 06 End output and confirm entry with

Q.
If one or several faults are stored:
Press
.
Fault number: 16685 P0301 -> 044....
Readout on display, e.g.:
Press
.
Cylinder 1 Combustion misfiring detected ->
Fault source and fault type appear in the display, e.g.:
Press
The stored faults are displayed in sequence.
Enter function 06 End output and confirm entry with

Q.
Rectify the faults displayed by referring to the fault table Chapter 01-2. Note When carrying out testing and removal and installation operations faults such as connector unplugged or CAN bus faults, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
Enter function 00 for Automatic test sequence and

confirm with Q . The Vehicle system tester -V.A.G 1552- sends all the known address words one after the other.
Erasing fault memory

Test conditions Note Whenever the fault memory is erased, it is necessary to generate a readiness code Chap. 01-3.
Fault eliminated Fault memory interrogated 01-1 page 3

Note After fault elimination the fault memory must again be interrogated and subsequently erased.
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Self-diagnosis I
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Enter function 05 Erase fault memory and confirm

with Q . Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Vehicle system test Fault memory was erased ->
Select function 06 End output and confirm with Q . Perform a test drive. Then, again interrogate the fault
memory. No fault must be displayed.
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1 - Exhaust gas recirculation solenoid valve -N182 - AC compressor engagement 3 - Solenoid valve for charge pressure control -N754 - Change-over valve for intake manifold flap -N2395 - Glow period warning lamp -K296 - Radiator fan control 7 - Glow plug relay -J528 - Low heat output relay -J3599 - High heat output relay -J36010 - Fault lamp Note
Actuation of the individual control elements is limited
to 30 seconds.
If the actuator diagnosis must be repeated without the
engine being started in the meantime, switch off ignition for about 20 seconds. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Fuses according to current flow diagram O.K.

Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
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Enter function 03 Final control diagnosis.
Readout on display: The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Actuator diagnosis Exhaust gas recirculation valve -N18
->
Testing Exhaust gas recirculation valve -N18 Chap. 23-1. .

Actuator diagnosis AC compressor engagement ->
Press
Readout on display: This test step is also activated on vehicles without AC system. Disregard display.
Press
.
Actuator diagnosis -> Charge press.control solenoid valve -N75
Readout on display: The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Test charge pressure control solenoid valve -N75 Chap. 23-1. .

Actuator diagnosis -> Intake manif.flap change-over valve-N239
Press
Readout on display: The engine must stop. If the engine does not stop:
Switch off ignition. Inspecting Intake manifold flap change-over valve

-N239- Chap. 23-1.
Continue final control diagnosis with the engine off

and the ignition switched on.
Press
.
Actuator diagnosis Glow period warning lamp -K29 ->
Readout on display: The warning light for glow period must flash. If the warning light for glow period does not flash:
Testing Glow period warning lamp - K29- Current

Flow Diagrams, Fault Finding Electrics and Fitting Locations.
Press
01-1 page 6
Self-diagnosis I
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FABIA 2000 1.9/96 TDI Engine, Fuel Injection Readout on display: Radiator fan must start running at 30 second intervals and stop. If the fan does not run:
01
Actuator diagnosis Radiator fan control ->
Testing radiator fan and radiator fan control unit

-J293- Current Flow Diagrams, Fault Finding Electrics and Fitting Locations. .
Actuator diagnosis Glow plug relay -J52 ->
Press
Readout on display: The relay must click. It is also possible to observe the relay switching on and off by the interior light becoming brighter or darker (caused by the high power consumption of glow plugs). If the relay does not click:
Test glow plug relay -J52- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis Low heat output relay -J359 ->
Readout on display: The relay must click. If the relay does not click:
Test low heat output relay -J359- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis High heat output relay -> -J360
Readout on display: The relay must click. If the relay does not click:
Test high heat output relay -J360- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
.
Actuator diagnosis Fault lamp ->
Readout on display: The fault lamp must flash. If the fault lamp does not flash:
Test fault lamp Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations.
Press
.
Vehicle system test Select function XX Q. HELP
Readout on display:
Select function 06 End output and confirm with
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Self-diagnosis I
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01-2
Self-diagnosis II
Fault codes 16485 to 19561

Note
The fault table is ordered according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g.. P0107) can be ignored (at present only
valid for USA).

Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the ve-
hicle system tester.

If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth
connections according to current flow diagram. Replace component only if these tests do not reveal any fault. This applies in particular if the fault is shown as sporadic (SP).
If the vehicle system tester -V.A.G 1552 - displays Information in the documentation; look up the relevant text in
the fault table according to the fault code indicated. Readout on -V.A.G 155216485 Air mass meter -G70 16684 Combustion misfiring detected 16685 Cyl. 1 combustion misfirings detected 16686 Cyl. 2 combustion misfirings detected 16687 Cyl. 3 combustion misfirings detected 16688 Cyl. 4 combustion misfirings detected 16705 Implausible sigEngine speed sender - nal G28 16706 No signal Engine speed sender G28 Implausible signal Rectifying fault
Test air mass meter -G70- Chap. 01-4, display group 003 Inspecting compression pressure 1.9/96 TDI Engine, Mechanics;
Rep. Gr. 15
Check unit injector Chap. 23-3
Inspecting Engine speed sender -G28- Chap. 23-1 Inspecting Engine speed sender -G28- Chap. 23-1 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248- Chap.

23-5 16725 Camshaft pos. sensor => Sender -G40 Implausible signal
Test camshaft position sensor -G40- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to current Inspect position of camshaft and rotor 1.9/96 TDI Engine, Mechanics; Rep. Gr. 15
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
16885 Vehicle speed signal
Implausible signal
Test vehicle speed signal Chapter 23-6
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Self-diagnosis II
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01
Readout on -V.A.G 155216944 Voltage supply 16946 Voltage supply 16947 Voltage supply 16955 Brake light switch -F 16989 Control unit defective 17552 Air mass meter -G70 17553 Air mass meter -G70 17554 Air mass meter -G70 17563 Intake manifold pressure sender -G71 17564 Intake manifold pressure sender -G71 17565 Intake manifold pressure sender -G71 17568 Intake manifold temp. sender -G72 17569 Intake manifold temp. sender -G72 17570 Fuel temperature sender -G81 17571 Fuel temperature sender -G81 17663 Coolant temperature sender -G62 17664 Coolant temperature sender -G62 Open circuit or short circuit to earth Short circuit to positive Supply voltage Short circuit to positive Open circuit or short circuit to earth Supply voltage Implausible signal Voltage too low Voltage too high Implausible signal Rectifying fault
Test cables to diesel direct injection system control unit - J248- ac-
cording to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test brake light switch -F- and Brake pedal switch -F47- Chap.
01-4, display group 006

23-5
Test air mass meter -G70- Chap. 01-4, display group 003 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

23-5
Test intake manifold pressure sender -G71- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit - J248- Chap.

23-5
Test charge pressure Chap. 01-4, display groups 000 and 010 Test intake manifold temperature sender -G72- Chap. 01-4, display group 007
Short circuit to earth Open circuit/ Short circuit to positive Short circuit to earth Open circuit/ Short circuit to positive Open circuit/ Short circuit to positive Short circuit to earth

23-5
Test fuel temperature sender -G81- Chap. 01-4, display group

007

23-5
Test coolant temperature sender -G62- Chap. 01-4, display group

007

23-5
01-2 page 2
Self-diagnosis II
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FABIA 2000 1.9/96 TDI Engine, Fuel Injection Readout on -V.A.G 155217668 Unit injector solenoid valve cyl. 1 -N240 17669 Unit injector solenoid valve cyl. 1 -N240 17670 Unit injector solenoid valve cyl. 1 -N240 17671 Unit injector solenoid valve cyl. 2 -N241 17672 Unit injector solenoid valve cyl. 2 -N241 17673 Unit injector solenoid valve cyl. 2 -N241 17674 Unit injector solenoid valve cyl. 3 -N242 17675 Unit injector solenoid valve cyl. 3 -N242 17676 Unit injector solenoid valve cyl. 3 -N242 17677 Unit injector solenoid valve cyl. 4 -N243 17678 Unit injector solenoid valve cyl. 4 -N243 17679 Unit injector solenoid valve cyl. 4 -N243 17795 Control unit defective 17810 Exhaust gas recirculation valve -N18 17849 Exhaust gas recirculation valve -N18 17910 Fuel pump relay -J17 17911 Load signal for alternator terminal DF 17931 Crash signal from airbag CU Short circuit to positive Open circuit or short circuit to earth Short circuit to positive Implausible signal Implausible signal Implausible signal Regulating limit exceeded Regulating limit not reached Implausible signal Regulating limit exceeded Regulating limit not reached Implausible signal Regulating limit exceeded Regulating limit not reached Implausible signal Regulating limit exceeded Regulating limit not reached Rectifying fault
01
Check unit injector Chap. 23-3 Inspecting fuel supply 1.9/96 TDI Engine, Mechanics;
Rep. Gr. 20

23-5
Test exhaust gas recirculation valve -N18- with final control diagnosis Chap. 01-1
Inspecting exhaust gas recirculation Chap. 23-4
Testing Current Flow Diagrams, Electrical Fault Finding and Fitting Locations fuel pump relay -J17-
Test alternator Electrical System; Rep. Gr. 27 Reading measured value block, display group 016 Chap. 01-4 Perform airbag system self-diagnosis Body Fitting Work;
Rep. Gr. 01.
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01
Readout on -V.A.G 155217948 Vehicle speed signal Signal too high Rectifying fault
17954 Charge pressure control solenoid valve N75 17957 Charge pressure control solenoid valve N75 17958 Charge pressure 17964 Charge pressure control 17965 Charge pressure control 17977 Cruise control system switch -E45
Short circuit to positive
Test vehicle speed signal Chapter 23-6 Test CAN databus lines Chapter 23-6 Test dash panel insert Electrical System; Rep. Gr. 90 Test charge pressure control solenoid valve -N75- with final control diagnosis Chap. 01-1
Open circuit or short circuit to earth Control difference Regulating limit not reached Regulating limit exceeded Implausible signal
Test charge pressure control solenoid valve - N75- with final control
diagnosis Chap. 01-1
Inspecting charge pressure control 1.9/96 TDI Engine, Mechanics; Rep. Gr. 21
Analyse measured value block, display groups 006 and 022

Chap. 01-4 Rep. Gr. 90
Read out fault memory of central control unit Electrical System; Adapt diesel direct injection system control unit - J248- to electronic
immobiliser Electrical System; Rep. Gr. 96
17978 Engine control unit blocked1) 18008 Voltage supply tml. 15 18009 Terminal 30 - voltage supply relay -J3172) 18017 Crash disconnect activated 18020 Engine control unit 18024 Glow period warning lamp -K29 18025 Glow period warning lamp -K29 18026 Glow plug relay -J52 18027 Glow plug relay -J52 18034 Data BUS drive Incorrectly coded Short circuit to positive Open circuit/ Short-circuit to earth Short circuit to positive Short circuit to earth Missing message from gearbox CU Voltage too low Implausible signal
Test immobiliser Electrical System; Rep. Gr. 96 Test voltage supply for diesel direct injection system control unit
-J248- Chap. 23-5
Test diesel direct injection system relay -J322- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Interrogate fault memory of airbag control unit Body Fitting Work;

Rep. Gr. 01
Replace airbag control unit Body Fitting Work; Rep. Gr. 69 Code diesel direct injection system control unit -J248- Chap. 23-5 Test glow period warning lamp -K29- with final control diagnosis
Chap. 01-1
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
Test CAN databus lines Chapter 23-6
01-2 page 4
Self-diagnosis II
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FABIA 2000 1.9/96 TDI Engine, Fuel Injection Readout on -V.A.G 155218039 Accelerator pedal position sender -G79 18040 Accelerator pedal position sender -G79 18043 Data BUS drive Signal too high Rectifying fault
01
Test accelerator pedal position sender -G79- Chap. 01-4, display

group 002
Supply voltage
Missing message from air conditioning system CU Missing message from airbag CU missing message form electron. CU
Test CAN databus lines Chapter 23-6 Interrogate air conditioning system control unit fault memory
Heating, Air conditioning; Rep. Gr. 87
18044 Data BUS drive
Test CAN databus lines Chapter 23-6 Interrogate fault memory of the airbag control unit Body Work;
Rep. Gr. 01
Test CAN databus lines Chapter 23-6 Interrogate fault memory of central control unit Electrical System;
Rep. Gr. 90
18047 Implausible sig1/2 for accelerator nal pedal position sender G79+G185 18048 Control unit defective 18056 Data BUS drive 18057 Data BUS drive defective
Test accelerator pedal position sender -G79- Chap. 01-4, display

group 002

23-5

23-5
Missing message from ABS CU Missing message from combiinstrument
Test CAN databus lines Chapter 23-6 Interrogate fault memory for engine control unit Chapter 01-1 Test CAN databus lines Chapter 23-6 Interrogate fault memory of ABS control unit Running Gear; Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Interrogate fault memory of dash panel insert Electrical System;
Rep. Gr. 90
18062 Interrogate fault memory of combiinstrument 18065 Air conditioning system inlet/outlet 18067 Radiator fan control 1 Short circuit to positive Short circuit to positive
Perform self-diagnosis of the dash panel insert Electrical System;

Rep. Gr. 90
Test AC compressor control with final control diagnosis Chap. 011
Test radiator fan control with final control diagnosis Chap. 01-1 Test cables for short circuit to positive or earth Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
18071 Actuation of unit injector solenoid valve 18072 Actuation of unit injector solenoid valve 18073 Actuation of unit injector solenoid valve
Short circuit to positive Electrical fault in the circuit Mechanical fault
Replace unit injector Chap. 23-2
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01
Readout on -V.A.G 155218074 Unit injector solenoid valve cyl. 1 -N240 18075 Unit injector solenoid valve cyl. 2 -N241 18076 Unit injector solenoid valve cyl. 3 -N242 18077 Unit injector solenoid valve cyl. 4 -N243 18080 Actuation of radiator fan 1 18090 Data BUS drive Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Electrical fault in the circuit Open circuit or short circuit to earth implausible message from ABS control unit Implausible message from electron. CU Missing message from combiinstrument Rectifying fault
Test radiator fan control with final control diagnosis Chap. 01-1 Test cables for open circuit or short circuit to earth Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations.
Test CAN databus lines Chapter 23-6 Interrogate fault memory of ABS control unit Running Gear;
Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Interrogate fault memory of central control unit Electrical System;
Rep. Gr. 90
19456 Glow period warning lamp -K29-
Test CAN databus lines Chapter 23-6 Test accelerator pedal position sender -G79- Chap. 01-4, display
group 002
19458 Implausible sigKick-down switch -F8- nal 19459 Short circuit to Low heat output relay - positive J359 19461 High heat output relay -J360 19463 Camshaft pos. sensor => Sender -G40 Short circuit to positive No signal
Test low heat output relay -J359 - with final control diagnosis
Chap. 01-1
Test high heat output relay -J360 - with final control diagnosis
Chap. 01-1

Inspect position of camshaft and rotor 1.9/96 TDI Engine, Mechanics; Rep. Gr. 15 Signal outside tolerance
19464 Camshaft pos. sensor => Sender -G40

Remove open circuit in wiring or short circuit according to current Inspect position of camshaft and rotor 1.9/96 TDI Engine, Mechanics; Rep. Gr. 15
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
19560 Intake manifold flap change-over valve N239 19561 Intake manifold flap change-over valve N239
Short circuit to positive
Test intake manifold flap changeover valve -N239- with final control
diagnosis Chap. 01-1
Open circuit or short circuit to earth
01-2 page 6
Self-diagnosis II
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01
1)
2)
When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault. Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
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01-2 page 8
Self-diagnosis II
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01-3
Self-diagnosis III
Readiness code Reading readiness code

Operation The readiness codes are two 8-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system is successfully performed (e.g. exhaust gas recirculation system), the relevant position of the readiness code switches from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that the systems operate according to the specifications. If a fault is detected during diagnosis, it is then stored in the fault memory. The readiness code is erased through deletion of the fault memory, that is all relevant points will be set to 1. Generation of readiness code refers to the activation of the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems etc. Procedure Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Connect vehicle system tester -V.A.G 1552- and enter

address word 01 Engine electronics Chap. 01-1. display group number 017. Readout on display:
Select function 08 Read measured value block and

Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 1 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel supply Ignore Meaning
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01
Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Meaning
If the specified values are not reached, generate readiness code 01-3 page 2.
Press key. Select function 06 End output and switch ignition off.
Generating readiness code

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
All electrical consumers, e.g. lights and rear window

heater switched off.
Intake air temperature must be below 60C display

group 007, display field 3
Coolant temperature at least 83C display group

007, display block 4
Procedure
Connect vehicle system tester -V.A.G 1552-. Select
address word 01 Engine electronics Chapter 011. Note
Certain work steps must be carried out twice, in order to achieve the readiness code.
Work step 1: Interrogating fault memory
Enter function
0 2 Interrogate fault memory and X faults detected
confirm with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
01-3 page 2
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01
Rectify the faults by referring to the fault table

Chapter 01-2. If no fault is stored:
Press
Work step 2:Erasing fault memory
Enter function
with Q . Note
0 5 Erase fault memory and confirm
The readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Vehicle system test The fault memory is erased ->
Press
Work step 3: Switch off ignition
Wait at least 5 seconds with ignition OFF.

Note This point is important, because with certain diagnoses the slowing down of the control unit must be ended. Otherwise readiness code cannot be generated.
Work step 4: Switch on ignition
Wait at least 10 seconds with ignition ON.

Charge pressure sender is adapted to atmospheric pressure sender.
Work step 5: 1. Testing fuel supply and other systems
Start engine. Function

0 8 Read measured value block and then
select display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed. Readout on display:
Reading measured value block 1 -> 2500 rpm 4.6 mg/s 2.0 CA 94.2 C
Work step 6: 1. Testing exhaust gas recirculation
Increase engine speed to 1600 rpm up to 1700 rpm

and maintain it for at least 10 seconds in this range.
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01-3 page 3
01
Readout on display: In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for generation of readiness code for exhaust gas recirculation).
Work step 7: Switch off ignition
Wait at least 5 seconds with ignition OFF.

Work step 8: Switch on ignition
Wait at least 10 seconds with ignition ON.

Work step 9: 2. Testing fuel supply and other systems
Start engine. Function

0 8 Read measured value block and then select display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed. Readout on display:
Work step 10: 2. Testing exhaust gas recirculation
Increase engine speed to 1600 rpm up to 1700 rpm

and maintain it for at least 10 seconds in this range. Readout on display:
Press Enter
C. 0 1 7 for display group 017 and read readiReading measured value block 00000000 00000110 10000000 17 -> 00000000
ness code. Readout on display: Specification in display field 2: 00000110 Specification in display field 4: 00000000
Press . If the specified values are not reached, repeat once

again procedure for generating readiness code 01-3 page 2.
Work step 11: Interrogating fault memory
Enter function
0 2 Interrogate fault memory and X faults detected
confirm with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
01-3 page 4
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01
Rectify the faults by referring to the fault table
Chapter 01-2 and again generate readiness code 01-3 page 2.
If no fault is stored:
Press
.
Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Readiness code was successfully generated, if no fault is stored after two work sequences of the test procedure in the fault memory for the engine control unit and if the following display appears in the channel 017.
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Self-diagnosis III
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01
01-3 page 6
Self-diagnosis III
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01-4
Self-diagnosis IV
Reading measured value block

-V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Coolant temperature must be at least 75C. All electrical components, e.g. lights and rear window
heater, must be switched off.
If vehicle is equipped with air conditioning, this must

be switched off.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Enter function 08 Read measured value block and

confirm the entry with key Q .
Enter display group 01-4 page 1.
Display groups 001 to 022, engine idling

Display group 001 in idle (engine warm, coolant temperature not below 75 C)
xxx.x C 4 < Display field Coolant temperature Fuel delivery duration (set value) Injection rate Engine speed Specification 75,0110.0C 3...8 KW 3,09.0 mg/s 800950 rpm Analysis ---- 01-4 page 1 ---
Read measured value block 1 xxx rpm 1 xx.x mg/s 2 x.xx KW 3
< Readout on display
Analysis: Display group 001, display field 2 - Injection rate
Display -V.A.G 1552below 3.0 mg/s above 9.0 mg/s
Rectifying fault
Check unit injectors Chap. 23-3. Warm up engine by running at high revs and repeat test. Check unit injectors Chap. 23-3.
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01
xxx.x C 4 < Display field Coolant temperature Operating position Accelerator pedal position Engine speed Specification 75,0110.0C 010 0,0 % --Analysis -- 01-4 page 2 01-4 page 2 01-4 page 1
Read measured value block 2 xxx rpm 1 xxx.x % 2 xxx 3
Analysis: Display group 002, display field 2 - Accelerator pedal position
Display -V.A.G 15521100,0%
Rectifying fault
Test accelerator pedal position sender -G79- Current Flow Diagrams,

Analysis: Display group 002, display field 3 - Operating position

Meaning, if display positions = 1 X X 1 0 X 1 Operating position Air conditioning switched on Idling switch closed (accelerator pedal not pressed) Ignore
xxx % 4 < Display field On/off ratio (actuation) of exhaust gas recirculation valve drawn in air mass (actual) drawn in air mass (nominal) Engine speed Specification 4075% Analysis ---
Read measured value block 3 xxx rpm 1 xxx mg/s 2 xxx mg/s 3
210...350 mg/s 230...310 mg/s ---
01-4 page 3 01-4 page 3 01-4 page 1
01-4 page 2
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Analysis: Display group 003, display field 2 - inducted air mass (set value)
Display -V.A.G 1552above 310 mg/s
Rectifying fault
Warm up engine by running at high revs and repeat test.
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Display -V.A.G 1552below 210 mg/s
Rectifying fault
above 350 mg/s
Test exhaust gas recirculation Chap. 23-4. Inspect intake system for leaks. Warm up engine by running at high revs and repeat test. Engine idles for too long, briefly blip throttle. Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
xx.x KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -3+3 KW 3,08.0 KW 4 BTDC2 ATDC --Analysis 01-4 page 3 -- 01-4 page 3 01-4 page 1
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Display -V.A.G 1552less than 4 BTDC
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 004, display field 4 - Synchronizing angle
Display -V.A.G 1552above 3 KW or under -3 KW
Rectifying fault
Test camshaft position sensor -G40- Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations.
Inspect position of camshaft and rotor 1.9/96 TDI Engine, Mechanics;

Rep. Gr. 15.
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Self-diagnosis IV
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01
xxx 4 < Display field Operating condition of the cruise control system Accelerator pedal position Status of the brake and clutch pedal switch Vehicle speed Specification xxx 0% 000 0 km/h Analysis 01-4 page 4 01-4 page 2 01-4 page 4 ---
Read measured value block 6 xxx km/h 1 xxx 2 xx.x % 3
Analysis: Display group 006, display field 2 Brake pedal or clutch pedal monitoring
Meaning, if display positions = 1 X X X 1 1 1 Operating position Brake light switch -F- closed (brake pedal operated) Brake pedal switch -F47- opened (brake pedal operated) Clutch pedal switch -F36- opened (clutch pedal operated)
Analysis: Display group 006, display field 4 - Operating condition of cruise control system
Display 0 1 255 Operating position Vehicles with activated cruise control system, switch in position OFF Vehicles with activated cruise control system, switch in position ON Vehicle without cruise control system or cruise control system function in engine control unit not activated
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Display group 007 with ignition switched on (engine cool and standing)
xxx.x C 4 < Display field Coolant temperature Intake manifold temperature Status of the fuel cooling Fuel temperature
1)
Read measured value block 7 xxx.x C 1 xxx % 2 xxx.x C 3
Specification approx. ambient temperature 1) approx. ambient temperature 1) 0% approx. ambient temperature 1)
Analysis 01-4 page 5 01-4 page 5 -- 01-4 page 5
It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant sender.
Analysis: Display group 007, display field 1 - Fuel temperature
Display -V.A.G 1552continuously 40.5C
Rectifying fault
Inspecting Fuel temperature sender -G81- Chap. 23-1.
Analysis: Display group 007, display field 3 - Intake manifold temperature
Display -V.A.G 1552continuously 135.9C
Rectifying fault
Inspecting Intake manifold temperature sender - G72- Chap. 23-1.
Analysis: Display group 007, display field 4 - Coolant temperature
Display -V.A.G 1552continuously -5.4C
Rectifying fault
Inspecting coolant temperature sender -G62- Chap. 23-1.

In the event of a fault the fuel temperature is displayed instead.
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Self-diagnosis IV
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xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 20...50% Analysis ---
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3
900...1150 mbar 900...1100 mbar ---
---- 01-4 page 1
x.xx mg/s 4 < Display field Smooth running control injected quantity cylinder 4 Smooth running control - injected quantity cylinder 3 Smooth running control - injected quantity cylinder 2 Smooth running control - injected quantity cylinder 1 Specification -2,80+2.80 mg/s -2,80+2.80 mg/s -2,80+2.80 mg/s -2,80+2.80 mg/s Analysis 01-4 page 6
Read measured value block 13 x.xx mg/s 1 x.xx mg/s 2 x.xx mg/s 3
01-4 page 6 01-4 page 6 01-4 page 6
Analysis: Display group 013, display field 1 through 4 - Idle smoothness regulator
The injection system has an idle smoothness regula-
tor. It is possible to detect differences in performance between individual cylinders (part tolerances, injector flow, compression etc.) and to compensate for these by selectively metering the quantity injected in the idling speed range.
Differences are detected in the idling speed range on
the basis of the signal supplied by the engine speed sender which supplies four signals to the control unit for each crankshaft revolution. If the signals have the same rhythm, the cylinder have the same output. If a cylinder has a lower output, the crankshaft will need more time for the next half crankshaft rotation. As opposed to this a high output cylinder will accelerate the crankshaft to such an extent that it will need less time.
Once the control unit has identified a deviation, the
relevant cylinder will immediately be supplied with a greater or smaller injection rate until the engine again runs smoothly.
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Self-diagnosis IV
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+ mg/s: The relevant cylinder has less output and is
01
therefore supplied with more fuel.

- mg/s: The relevant cylinder has more output and
is therefore supplied with less fuel.
Display group 016 in idle

< Readout on display xx.x V 4 < Display field Supply voltage of the engine control unit Heating element control Auxiliary heating (operating condition) Generator capacity Specification 12,514.5 V xx xxxxxxxx 595% Analysis 01-4 page 8 01-4 page 7 01-4 page 7 ---
Read measured value block 16 xxx % 1 xxxxxxxx 2 xx 3
Analysis: Display group 016, display field 2 - Auxiliary heating (operating condition)
Meaning, if display positions = 1 X X X X X X X X 1 1 1 1 1 1 1 1 Additional heating deactivated, because: Coolant temperature greater than 7080C or intake air temperature greater than +5C AC generator defective Battery voltage below 9 V Engine speed less than 860 rpm Engine start within the last 10 seconds Coolant temperature sender -G62- or Intake manifold temperature sender -G72- or end stage for auxiliary heating defective Ignore Ignore
Analysis: Display group 016, display field 3 Control of the heating elements
Meaning, if display positions = 1 X 1 X 1 Operating position Low heat output relay -J359- on High heat output relay -J360- on
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Self-diagnosis IV
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Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Display -V.A.G 1552below 12.5 V Rep. Gr. 27.
Rectifying fault
Test AC generator and battery voltage, charge battery Electrical System; Increase engine speed slightly for a few minutes and switch off additional
consumers.
above 14.5 V
Test supply voltage of engine control unit Chap. 23-5. Rectify any current drain. Test voltage regulator, replace if necessary Electrical System;
Rep. Gr. 27.
Remove start aid cable or quick charger.
Display group 018 in idle

< Readout on display xx 4 < Display field Unit injector solenoid valve cyl. 4 Unit injector solenoid valve cyl. 3 Unit injector solenoid valve cyl. 2 Unit injector solenoid valve cyl. 1 Specification 0 0 0 0 Analysis 01-4 page 8 01-4 page 8 01-4 page 8 01-4 page 8
Read measured value block 18 xx 1 xx 2 xx 3
Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors
Display -V.A.G 1552If number instead of zero
Rectifying fault
Test injector unit Chap. 23-3. Inspecting fuel supply 1.9/96 TDI Engine, Mechanics; Rep. Gr. 20.
Display group 022, engine idling

x 4 < Display fields Operating state of air conditioning Operating state of charge pressure control Operating state of cruise control Operating condition of the cruise control system Specification 0 0 xxxxxx x Analysis 01-4 page 9 01-4 page 9
Read measured value block 22 x 1 xxxxxx 2 x 3
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Self-diagnosis IV
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Analysis: Display group 022, display field 1 - operating state of cruise control system
Operating condition of the cruise control system 0 1 9 Vehicle without CCS, or CCS function in engine control unit not activated Vehicles with activated CCS, switch in position OFF Vehicles with activated CCS, switch in position ON
Analysis: Display group 022, display field 2 - operating state of cruise control system
Cruise control Switch B on ON Switch B on RES Switch A operated Switch B to OFF before operating point Switch B to OFF locked
Display field 2 000011 001011 000111 000001 000000
Display groups 004 through 011 at full load

Note
Accelerate vehicle at full throttle before inspecting. The measured values must be read off or printed out
once an engine speed of 3000 rpm is reached (2nd person required).

Pay attention to safety precautions for test drives
Chapter 23-1.
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Self-diagnosis IV
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01
Display group 004 under full load (test drive in 2nd gear coolant temperature not below 75 C)
x.xx KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -3...+3 KW 1628 KW 13 BTDC21 BTDC 28003200 rpm Analysis ---------
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3
xx.x mg/s 4 < Display field Injection rate limit based on drawn in air mass (smoke prevention) Injection rate limit based on engine speed (torque limit) Injection rate (driver's instruction) Engine speed Specification 47,060.0 mg/s Analysis 01-4 page 11
Read measured value block 8 xxx rpm 1 xx.x mg/s 2 xx.x mg/s 3
47,051.0 mg/s 65,070.0 mg/s 28003200 rpm
01-4 page 10 01-4 page 10 ---
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Display -V.A.G 1552below 65.0 mg/s
Rectifying fault
Repeat test at full throttle. Test accelerator pedal position sender -G79- Current Flow Diagrams,
Analysis: Display group 008, display field 3 - Injection rate limit over speed (torque limit)
Display -V.A.G 1552below 47.0 mg/s
Rectifying fault
Read off set value at 3000 rpm.
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Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Display -V.A.G 1552below 47.0 mg/s ing and Fitting Locations.
Rectifying fault
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find Test exhaust gas recirculation Chap. 23-4.
xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 40...95% Analysis ---
Read measured value block 11 xxxx rpm 1 xxxx mbar 2 xxxx mbar 3
2100...2600 mbar 2200...2400 mbar 2800...3200 rpm
-----
Analysis: Display group 011, display field 3 - intake manifold pressure (charge pressure)
Display -V.A.G 1552below 2100 mbar or over 2600 mbar Rep. Gr. 21.
Rectifying fault
Inspecting charge pressure control 1.9/96 TDI Engine, Mechanics;
Display group 125 - CAN databus

Display group 125 with ignition switched on
Airbag 1 4 < Display field Airbag control unit Dash panel insert CU ABS control unit not assigned Specification Airbag 1 Combi 1 ABS 1 --Analysis 01-4 page 12 01-4 page 12 01-4 page 12 ---
Read measured value block 125 ABS 1 1 2 Combi 1 3
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Analysis: Display group 125, display field 2, 3 and 4
Display -V.A.G 15520
Rectifying fault
Test CAN databus Chap. 23-6.
01-4 page 12
Self-diagnosis IV
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23
23 Fuel Formation, Injection

23-1 Diesel Direct Injection System
Safety measures
Observe the following points to prevent injury to persons and/or damage to the injection and preheating system:
Disconnect and connect wires of the injection and pre-
heating system and measuring device wires when the ignition is switched off.
When the battery is disconnected and reconnected,
carry out rework Electrical System; Rep. Gr. 27.
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the
rear seat and have a second person operate them there. If the test and measuring equipment is operated from the front passenger seat, this can result in injuries to the persons sitting on that seat in the event of an accident which involves the front passenger airbag being deployed.
Rules of cleanliness
Pay careful attention to the following rules of cleanliness when working on the fuel supply or fuel injection systems:
Thoroughly clean the connection points and their sur-
roundings before releasing.

Place removed parts on a clean surface and cover. Do
not use fuzzy cloths!

Carefully cover or close opened components if the re-
pair is not completed immediately.

Only install clean parts. Remove spare parts from
their wrapping immediately before fitting. Do not use parts that have been stored without wrapping (e.g. in tool cabinets etc.).
When the system is open: avoid working with com-
pressed air. Avoid moving the vehicle.

Also make sure no diesel fuel runs onto the coolant
hoses. If this is the case clean the hoses immediately. Replace immediately any hoses which have suffered damage.
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Diesel Direct Injection System
23-1 page 1
23
Overview of fitting locations
Components A through H are not represented in the overview figure. A - Diesel direct injection system relay -J322 on relay carrier Current 1 2 3 Flow Diagrams, Electrical Fault Finding and Fitting Locations B - Glow plug relay -J52 on relay carrier Current Flow Diagrams, Electrical Fault Finding and Fitting Locations C - Low heat output relay -J359 on relay carrier Current Flow Diagrams, Electrical Fault Finding and Fitting Locations D - High heat output relay -J360 on relay carrier Current Flow Diagrams, Electrical Fault Finding and Fitting Locations 11 10 9 E - Fuel pump relay -J17 on relay carrier Current Flow Diagrams, Electrical Fault Finding and Fitting Locations F - Sender for accelerator pedal position -G79 in footwell on the accelerator pedal Fig. 1 in 23-1 page 3 G - Brake light switch -F- and Brake pedal switch -F47 in footwell on the brake pedal Fig. 1 in 23-1 page 3 H - Clutch pedal switch -F36 in footwell on the clutch pedal Fig. 1 in 23-1 page 3 1 - Valve block Component parts of the valve block are: intake manifold flap change-over valve -N239-, specified resistance 25...45 Solenoid valve for exhaust gas recirculation -N18-, specified resistance 14...20 solenoid valve for charge pressure control -N75-, specified resistance 25...45 2 - Mechanical exhaust gas recirculation valve 3 - Sender for the coolant temperature -G62 Specified resistance Fig. 2 in 23-1 page 3 4 - Air mass meter -G705 - Diesel direct injection system control unit -J2486 - Fuel temperature sender -G81 Specified resistance Fig. 3 in 23-1 page 4 7 - Connector 3-pin, grey for engine speed sender -G28 3-pin, black
S23-0156
23-1 page 2
Edition 09.04 S00.5328.01.20
FABIA 2000 1.9/96 TDI Engine, Fuel Injection for the camshaft position sensor -G40Engine speed sender -G28 specified resistance between contacts 1 and 2: 450...550 Camshaft position sensor -G40Intake manifold pressure sender -G71- with intake manifold temperature sender -G72 Specified resistance Fig. 2 in 23-1 page 3 Fuel filter repairing 1.9/96 TDI Engine, Mechanics; Rep. Gr. 20
23
8910 11 -
Fig. 1:
Components in footwell
1 - Clutch pedal switch -F362 - Brake light switch -F- and Brake pedal switch -F473 - Sender for accelerator pedal position -G79-
3 2
1
S24-0374
Fig. 2:
Resistance of coolant temperature sender -G62- and of intake manifold temperature sender -G72-
The specification in field -A- applies to the temperature range 0 to 50 C, specification in field -B- applies to the temperature range 50 to 100C. Read out examples:
The specification for a temperature of 30C is 1500 to
2000
375
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23-1 page 3
23
Fig. 3: Resistance of fuel temperature sender -G81-
The specification in field -A- applies to the temperature range 0 to 65C, specification in field -B- applies to the temperature range 65 to 100C. Read out examples:
4270
660
23-1 page 4
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23
Disassembling and assembling intake manifold

1 - Intake manifold 2 - O-ring replace 3 - Induction pipe with exhaust gas recirculation valve and intake manifold flap 4 - Mechanical exhaust gas recirculation valve 5 - 10 Nm 6 - Bracket 7 - Vacuum setting element 8 - Vacuum hose of valve block 9 - 25 Nm 10 - Exhaust return pipe to exhaust pipe 11 - Gasket replace 12 - 6 Nm 13 - Sealing sleeve 14 - 5 Nm
Removing and installing air filter

Removing
Loosen spring strap clamp -1- on the air guide hose

and remove the hose from the air filter.
Disconnect ventilation hose -2- and the plug on the air

mass meter -3-.
1 2 3 4 5
Remove the air deflector -4- from the air filter. Unscrew the fixing screw -5- from the air filter (tightening torque: 8 Nm).
Carefully remove air filter from the top.

Installing
Note Pay attention to correct positioning of the stop buffer on the bottom part of the air filter (front and rear side).
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S23-0125
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23
Installation is carried out in the reverse order.
Disassembling and assembling the air filter

1 - Air guide hose To intake manifold Check fitting position 2 - Spring strap clip 3 - 2 Nm 4 - Top part of air filter cover 5 - Filter insert 6 - Bottom part of the air filter cover 7 - 2 Nm 8 - Air deflector to the lock carrier 9 - Air mass meter -G70 inspect Chapter 23-3
3 9 5
S23-0124
23-1 page 6
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23-2
Disassembling and assembling the unit injector
Workshop Manual OCTAVIA 1.9 l/96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 23
Edition 07.03 S00.5328.00.20
23-2 page 1
23
23-2 page 2
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23-3
Testing components
Workshop Manual OCTAVIA 1.9 l/96 kW (TDI) Engine, Fuel Injection and Glow Plug System; Rep. Gr. 23
Edition 07.03 S00.5328.00.20
Testing components
23-3 page 1
23
23-3 page 2
Testing components
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23
23-4
Testing exhaust gas recirculation

1
Connection diagram of vacuum hoses for exhaust gas recirculation

123456Valve block Non-return valve To the brake servo unit Vacuum pump Mechanical exhaust gas recirculation valve To air filter
2 3 6 5 4
S23-0155

Vehicle system tester -V.A.G 1552 Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test sequence
The exhaust gas recirculation function is checked in function 04 (basic setting). As a result of this procedure the exhaust gas recirculation valve is pulsed every 10 seconds, so that the extreme values for the exhaust gas recirculation (air mass meter) can be read off in measured value block 003 in display field 3.
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.
Enter function 04 basic setting and select display

group number 003. Note After selecting display group number 003 and confirming with Q , the idling speed is increased by the engine control unit in display field 1 to 13801420 rpm. The display in display field 2 must switch between EGR not active and EGR active every 10 seconds. The following readouts must fluctuate in display fields 3 and 4: Note If a constant value of 539 mg/stroke and higher is shown in display field 3, test the air mass meter Chapter 23-3.
System in basic setting 3 1410 rpm EGR not active
-> 450 mg/H
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23-4 page 1
23
EGR not active: Specification in display field 3: 440600 mg/H specified value in display field 4: 1822 % EGR active: Specification in display field 3: 160340 mg/H specified value in display field 4: 6367 % If the specified values are not reached:
Inspecting mechanical exhaust gas recirculation valve

1.9/96 TDI Engine, Mechanics; Rep. Gr. 26. they are connected properly.
Inspect 23-4 page 1 vacuum hoses to see that Test solenoid valve for activated charcoal filter system
-N18- with final control diagnosis Chapter 01-1.
23-4 page 2
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23
23-5
Engine control unit
Testing voltage supply for engine control unit

-V.A.G 1551/3, 3A, 3B oder 3C Handheld multimeter (e.g. -V.A.G 1526 A-) Measuring tool set (e.g. -V.A.G 1594 A- or
- V.A.G 1594 C-)

Test box -V.A.G 1598/31-
Test conditions
Fuses o.k. Battery voltage at least 11.5 volts AC generator O.K.

Test sequence
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and enter address word 01 Engine electronics Chapter 01-1.
Enter function 08 read measured value block and

select display group 012. Readout on display:
Reading measured value block 11111111 0.00 12.5 V 12 -> 28.5 C
Read off value indicated in display field 3.

Specified value: approx. battery voltage (constant)
Enter function 06 End output and confirm with
Q.
If the value displayed fluctuates or if the battery voltage is not reached:
Switch off ignition. Connect test box -V.A.G 1598/31- at the wiring loom
of the engine control unit Chap. 23-3.
Connect handheld multimeter as follows:

Test box -V.A.G 1598/ 31-, bush 1, 2 + 4, 5 37 + 4, 5 Specification approx. 0 V approx. 0 V
Switch on ignition. Measure once again the voltage between the bushes.
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Engine control unit
23-5 page 1
23
Test box -V.A.G 1598/ 31-, bush 1, 2 + 4, 5 37 + 4, 5 Specification approx. battery voltage approx. battery voltage
If the specified values are not reached:
Test diesel direct injection system relay -J322-.
Replacing diesel direct injection system control unit -J248Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure

ignition on and enter address word 01 Engine electronics Chapter 01-1. The vehicle system tester -V.A.G 1552- displays the control unit identification, e.g.:
038906019LA 1.9l R4 Coding 00102 EDC G000SG 1576 -> WSC XXXXX
Note Part No. of control unit and coding. Enter function 06 End output and confirm with
Removing
Q.
Switch off ignition. Remove air filter Chap. 23-1. Release the connector catches and unplug the connectors of the diesel direct injection control unit - J248-.
Press off catch pegs -arrows- to the outside and pull

out the control unit to the side.
Installing
Installation undertaken in the reverse order. After installing the diesel direct injection system control unit -J248-, it is then necessary to carry out the following steps:
Coding diesel direct injection system control unit

-J248- 23-5 page 3.
Adapt the new diesel direct injection system control
unit -J248- to the immobiliser control unit Electrical System; Rep. Gr. 96. 23-5 page 4.
S24-0373
For vehicles with cruise control system: Activate CCS
23-5 page 2
Engine control unit
Edition 09.04 S00.5328.01.20
23
Interrogate fault memory of new engine control unit

and erase fault memory, rectify any faults present Chap. 01-1.
Each time the fault memory is erased, it is then necessary to re-generate the readiness code Chapter 013.
Perform a test drive.

Note Comply with the applicable safety instructions during the test drive Chap. 23-1.
Once again interrogate the fault memory of the diesel

direct injection system control unit - J248-.
Coding diesel direct injection system control unit -J248If the code displayed does not match the vehicle or if the diesel direct injection system control unit -J248- has been replaced, it is then necessary to code the control unit as follows. Special tools, test and measuring equipment and auxiliary items required
-V.A.G 1551/3, 3A, 3B oder 3C-
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1.
Enter function 07 Code control unit.

Readout on display:
Coding control unit Enter code number xxxxx (0 -32767)
Enter code number by referring to table of codes and

confirm with Q . Table of codes: Control unit identification 038 906 019 LA Variant with air conditioning without air conditioning Code number 00102 00105
The vehicle system tester -V.A.G 1552- displays the control unit identification, e.g.:
038906019LA 1.9l R4 Coding 00102
EDC G000SG
1567 -> WSC XXXXX
Enter function 06 End output and confirm with Switch ignition off and on again.
Note
Q.
The entered coding is activated by switching the ignition on and off again.
Edition 09.04 S00.5328.01.20
Engine control unit
23-5 page 3
23
Activating and deactivating cruise control system (CCS)
-V.A.G 1551/3, 3A, 3B oder 3C-
Test condition
No fault in fault memory, interrogating fault memory

Chap. 01-1
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1. Read-out on display, e.g.: If G000SG is displayed, the cruise control system is active Readout on display: If 000SG is displayed, the cruise control system is not active
038906019LA 1.9l R4 Coding 00102 EDC 000SG 1576 -> WSC XXXXX 038906019LA 1.9l R4 Coding 00102 EDC G000SG 1576 -> WSC XXXXX
Press . Select function 11 login procedure.

Readout on display:
Login procedure Enter code number XXXXX
Enter code number as stated in the table.

Code number 11463 16167 Cruise control system (CCS) Activate CCS Deactivate CCS
Confirm with
Q. Q.
Select function 06 End output and confirm with
After activating the cruise control system perform a test drive as a functional test.
23-5 page 4
Engine control unit
Edition 09.04 S00.5328.01.20
23
23-6
Testing auxiliary signals
1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 23
Edition 07.03 S00.5328.00.20
23-6 page 1
23
23-6 page 2
Edition 07.03 S00.5328.00.20
28
28 Glow Plug System

28-1 Testing preheating system
1.9/74 TDI Engine, Fuel Injection; Rep. Gr. 28
Edition 07.03 S00.5328.00.20
Testing preheating system
28-1 page 1
28
28-1 page 2
Testing preheating system
Edition 07.03 S00.5328.00.20

Workshop Manual - TDI Engine Fuel Ingection ASZ

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Service

Service Department. Technical Information

Printed in Czech Republic S00.5328.00.20

Printed in Czech Republic S00.5328.00.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

List of Supplements to Workshop Manual

Edition 07.03 09.04

Subject Basic Edition Modifications in Rep. Gr. 01 and 23

Article Number S00.5328.00.20 S00.5328.01.20

Edition 09.04 S00.5328.01.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Edition 09.04 S00.5328.01.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

23 Fuel Formation, Injection

28 Glow Plug System

Edition 09.04 S00.5328.01.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Edition 09.04 S00.5328.01.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Properties of the self-diagnosis

Technical data of self-diagnosis

Edition 07.03 S00.5328.00.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Engine idling yes yes yes yes yes yes no yes no

Normal driving yes yes no no yes yes no yes no

-V.A.G 1551/3, 3A, 3B oder 3C-

V.A.G 1552 V.A.G 1551/3

Switch on the ignition or start 01-1 page 1 engine

Vehicle system test The control unit does not respond

Edition 07.03 S00.5328.00.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Operate the vehicle system tester by referring to the

Vehicle system test Enter address word XX

control unit version see spare parts catalogue)

spond to the vehicle, replace the control unit Chapter 23-5.

Interrogating and erasing fault memory

-V.A.G 1551/3, 3A, 3B oder 3C-

Interrogating fault memory

Edition 07.03 S00.5328.00.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Enter function 06 End output and confirm entry with

If one or several faults are stored:

Readout on display, e.g.:

Fault source and fault type appear in the display, e.g.:

The stored faults are displayed in sequence.

Enter function 06 End output and confirm entry with

Enter function 00 for Automatic test sequence and

Erasing fault memory

Fault eliminated Fault memory interrogated 01-1 page 3

Edition 07.03 S00.5328.00.20

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Enter function 05 Erase fault memory and confirm

-V.A.G 1551/3, 3A, 3B oder 3C-

Fuses according to current flow diagram O.K.

FABIA 2000 1.9/96 TDI Engine, Fuel Injection

Actuator diagnosis Exhaust gas recirculation valve -N18

Testing Exhaust gas recirculation valve -N18 Chap. 23-1. .

Test charge pressure control solenoid valve -N75 Chap. 23-1. .

Switch off ignition. Inspecting Intake manifold flap change-over valve

Continue final control diagnosis with the engine off

Testing Glow period warning lamp - K29- Current

Edition 07.03 S00.5328.00.20

Testing radiator fan and radiator fan control unit

Test glow plug relay -J52- Current Flow Diagrams,